Process for catalytic conversion reactions



May 18, 1943 I P. MATHER 2,319,620

PROCESS FOR CATALYTIC CONVERSION REACTIONS Filed Feb. 26, 1940 3 Sheets-Sheet l Ifim m l9 L WWW IL Hm H] l W NH] 1 i W EL WW1! l0 l [12! II4-\L F v I I I I p i I Miami l0 9/ 1'? fll' INVENTOR ATTORNEY Ma'y1s,"1943 P. MATHER 2,319,620 I rnocsss; FOR CATALYTIC CONVERSION REACTIONS Fild Feb. 26, 1940 s Sheets-Sheet 2 I'NVENTOR PERCY MATHER' ATTORNEY actants and reactivation of ems-M a, 1943 cum-1o STATES {PATENT s ear:

I 2,319,620 raocsss FOR caranmo cosvnasrou aaavrross Percy Mather, Chlw 111 Chicago, 111., a corpora- 011 Products mm! tion of Delaware Application February 26, 1940, Serial No.

assignor to Universal (claims. (01. 196-52) :The invention relates to an improved method for conducting catalytically promoted conversion reactions and particularly those of the type devoted to the conversion of hydrocarbons, as catalytic cracking, dehydrogenation, isomerizaticn, cyclization, reforming, etc., wherein heavy carbonaceous conversion products are .deposited on the catalyst and must be periodically removed therefrom to restore its activity;

In such reactions conversion of the hydrocarbuns is usually endothermic, in varying degrees,

' and reactivation oi the catalyst, which is exoburning the dethermic, is accomplished by posited carbonaceous materials therefrom in a stream of oxygen-containing gas,

The range of temperature conditions which may be employed with best results for any specific catalyst andcharging stock is relatively narrow and, during reactivation of the catalyst, care must .be exercised to prevent the development of, temperatures which cause destruction or permanent impairment to the activity of thecatalyst. For these reasons, it has heretofore been common practice to control temperatures during both processing of the hydrocarbon rethe catalyst by circulating a convective medium in indirect heat transfer relationwlth the catalyst, reactants and reactivating gases. with the relatively short alternate periods of processing and reactivation in eachreactor, which are ordinarily required for good results, this method of temperature control is one of the major items of expense both in the initial installation and in operation.

This invention provides a diflerent mode of operation and an apparatus for conducting the same in which the aforementioned conventional method 0! temperature control and its attendant expense is obviated in a simple and advantageous manner.

To accomplish the improved method of operation, the catalytic material employed to promote the conversion reaction is divided into'a plurality of relatively shallow beds in each reactor of the system and provision is made for dividing the stream of hydrocarbon reactants, which is supplied to the reactor inheated state, into a plurality of substantially equal smaller streams, each of which is passed through only one of the several catalyst beds, resulting fluid conversion products being thence removed from the reactor. During reactivation of the catalyst a stream of oxygen-containing rea'ctivatinggases, which is supplied to the reactor in heated state, is likewise divided into a plurality of subexternal temperature control.

employed, the temperature and rate at which the heated reactants are supplied to the reactor and the type of catalyst and charging stock employed) are the same but wherein the total reactants and reactivating gases are passed through the entire mass of catalyst and no external heating or cooling means are employed, the improved method of operation herein provided results in more uniform temperatures throughout the catalyst mass during processing and reactivation, a highermin'imum and higher average temperature in the catalyst mass durin throughout the Due to more \miform uniform deposition processing, a lower maximum and lower average temperature in the catalyst mass during reactivatiomas well as lower mass velocities and. hence lower pressure drop through the reactor. temperatures throughout the catalyst mass during processing, the deleterious heavy conversion products deposited on the catalyst mass are more uniformly distributed latter and the rate of decreasing catalyst activity is much lower. The more of deleterious carbonaceous material is also advantageous during reactivation since it materially assists in preventing the development of excessive temperatures at any point in the catalyst'mass.

Depending upon the type of catalyst and charging stock employed, the ratio of catalyst volume to reactants processed in a given time and the general level of temperature and pressure conditions utilized in conducting the process, the length of time desirable for continuous use oLthe catalyst in promotingthe cracking such reactmn may, due to other considerations, as optimum quality and yield of gasoline produced, by somewhat less or somewhat more than the length of processing time required to decrease the activity 0! the catalyst to a point where its reactivation is necessitated, and the spent relength of each processing period will correspond to whichever of the aforementioned times is the shorter. By properly controlling the relative proportions of oxygen. and inert ingredients in the reactivating gas stream and properly regulating the rate at which the reactivating gases are supplied to the reactor, the length of the reactivating period may be controlled to approximately correspond to the length of the processing periods. '7

In the accompanying diagrammatic drawings Fig. 1 is an elevation, shown partially in section, of a specific form of reactor embodying the features of the invention and in which the improved process steps provided by the invention may be conducted.

Fig. 2 is an enlarged cross-sectional detail of one of the catalyst trays 8 of Fig. 1.

Fig. 3 is an elevation, shown partially in section, of the upper and lower portions of a. modifled form of reactor embodying the features of the invention.

Fig. 4 is a diagram of a process flow wherein two reactors of the improved type provided by the invention are arranged for alternate processing of the hydrocarbons to be converted and reactivation of the catalyst in each reactor.

Referring to Figs. 1 and 2, an elongated cylindrical shell of the reactor, indicated by the reference numeral I, is provided with a lower head 2 and a removable upper head 4 which is flanged and bolted, as indicated at 5, to shell I. Inlet nozzle 6 is provided in the removable upper head 4 and outlet nozzle 1 i provided in the lower head 2.

A plurality of catalyst trays 8 are provided within shell I between its upper and lower heads and, as illustrated in Fig. 2, each of these mem bers comprises a relatively flat deck 9 having upturned edge portions III at its outer circumference and a central tubular member II extending from above the level of the upturned edges In to beneath the level of deck 9.

A pervious member I2 diagrammatically shown in Fig. 2 as a screen, although a perforate plate or the like may be substituted, is provided between the upturned edges I and deck 9 and extends from'the upturned edges II! to the central tubular member II. Screen I2 is attached, in the particular case here illustrated, to the uptumededges III of the tray by turning the outer edge of the screen downward and holding it between the tray and a ring-shaped member I3 which is welded or otherwise securedto the tray. A similar attachment comprising ring-shaped member I l anchors the inner edge of the screen to member II.

A relatively shallow bed of catalytic material, indicated at I in Fig. 1 is provided in each of the trays 8 above the member l2.

Openings IS in that-portion of member II disposed between screen I2 and deck 9 establish communication between the interior of the tubular member I I and the space I1 provided between the screen and the deck. In the case here illustrated, in order that each of the trays 8 may be identical, a ring-shaped member I8, having openings therethrough corresponding to openings I6, is provided on the interior of tube II and by partially rotating member I8 or moving it up or down, the effective area of the openings may be adjusted to suit requirements.

As illustrated in Fig. 1, the lower portion of member II of each of the trays nests within the upper portion of member II of the next lower tray in such a manner that the trays are spaced a short distance apart, to provide spaces I9 therebetween, and themembers II form a continuous central conduit through the reactor from the uppermost tray-to and through outlet I. Outlet nozzle 1 includes a portion 20 extending upwardly into the reactor and having an upper end similar to the upper end of members II of the trays I8, so that the lower ends of member I I of the lowermost tray nests within the upper end of member 20.

Each of the trays 8 is sufliciently smaller than the internal diameter of shell I that a space 2| is provided therebetween.

A baillefl is provided above the uppermost tray 8 within the reactor, this battle serving to direct the incoming reactants or reactivatlng gases, as the case may be from inlet 6 to the space M between the-outer edge of the trays and the inner surface of shell I.

In operation, the stream of heated reactants to be converted or the stream of hot oxygen-containing gases employed to reactivate the catalyst. as the case may be, enter the upper end of the reactor through nozzle 6 and flood the spaces II and I9, from which they flow as a plurality of separate streams of substantially equal volume through the catalyst beds l5 into the space I! of each of the trays and thence through the openings I6 into the tubular conduit formed by members I I. Thus, each of the separate streams of hydrocarbon vapors and reactivating gases pass through only one of the catalyst beds and then commingle in the central conduit with the streams from the other catalyst beds, the recommingled streams being discharged from the reactor through outlet nozzle 1.

Suitable packing material may be provided within the lower portion of the groove 26 at the upper end of each of the members I I, into which groove the lower end of member II of the next higher tray fits, the packing serving to prevent leakage from spaces l9 into the conduit formed by members II so as to prevent short circuiting of the catalyst beds by the reactants and reactivating gases.

- removed therefrom.

The ring-shaped members I8 in members II are preferably so adjusted that the effective area through openings I6 is progressively greater from 1 the uppermost to the lowermost tray so as to obtain a substantially equal volume of flow through each of the catalyst beds. I

The construction illustrated in Figs. 1 and 2 permits ready removal and replacement of the trays after the upper head 4 of the reactor is It automatically spaces and aligns the trays and permits free longitudinal expansion andcontraction of the tray assembly, the latter being supported only from the lower end of the reactor.

Many modifications of the specific form of apparatus illustrated in Figs. 1 and 2 may be provided without departing from the broader aspects of the invention. One such modification is illustrated in Fig. 3 which will now be described.

In Fig. 3 the outer cylindrical shell of the reactor is indicated at 30"and is provided with a flange 3| at its upper end to which the flanged removable upper head 32 is bolted. The lower head 33 is, in this case. as in Fig. 1, integral with the shell. The upper head 32 is provided with aninlet nozzle 34 and the lower head 33 is provided with an outlet nozzle 35.

. The catalyst trays 36 of Fig. 3 each comprise arelatively bottom portion 31 of each cracked, is supplied through line m and valve flat bottom portion 31 and upwardly extending inner and outer edges 38 and 39, respectively, which are provided with the respective openings 40 and GI. The openings in the inner member 38 are backed by a continuous pervious member such as screen 42, which is of such mesh as'to retain the catalyst particles of bed 43 in place, and a similar continuous pervlous member 60 is provided over the openings dl at the outer edge of the tray. I

Each tray the group rests upon the next succeeding lower tray, the bottom portion 31 of each tray serving as a cover for the next lower tray, and preferably, as here illustrated, a plurality of ring-shaped baifles 48 depend'trom the tray and extend partway into the catalyst bed 43 of the next lower tray to prevent short circuiting of the vapors and gases across, any space 45 which is left beneath the bottom of each tray and the top of the catalyst bed in the next lower tray.

A vapor tight joint is not required where the outer portions 39 oi'the trays meet but, preferably, the lower end of each of the inner edge portions 38 of the trays is constructed to upper edge of member 30 of the next lower tray bears to maintain a substantially gas-tight joint therebetween.

.An extension I" of outlet nozzle 30 protrudes upward into the shell of the reactor and termimates in an upper end which is received within the packing recess of A the lowermost tray to maintain a tight joint at the point of juncture of this traywith the outlet nozzle.

The uppermost tray is provided with a cover is provided with baiiles 4; and preferably the upper end of the tubular member formed by the walls 00 of the uppermost tray is closed by weld-v ing in a disc-shaped member 50 at this point.

with the trays in place in the reactor, theircircular inner walls 38 form a continuous central conduit extending from the uppermost through the lowermost tray to portion "of outlet nozzle 35, the interior of thisconduit being in communication thr' ugh ports 00 with the catalyst bed on each tray. The trays are sufllciently smaller in internal diameter of shell 30 to provide a substantial space 52 therebetween and a space II within the removable upper head 32 of the reactor communicates with opening through inlet nozzle 30.

Heated hydrocarbon vapors to be converted which extends substantially the full I length of shell 00. Their only means of egress from the uppermost to the lowermost tray to accomplish the same result.

Referring to Fig. 4; the hydrocarbon to be converted, which may comprise, for example. a

stream of hydrocarbon oil to be catalytleally receive suitable packing material 46, against which the external diameter than the space 50 and with the through line charged from I09 and line through the reactors the reactivating gas stream I02 tc-heating coil I03 disposed in heater I00 wherein the oil is porized and heated toapproximately the temperature at which it is desired to conduct the catalytic cracking reaction. I j

The resulting heated hydrocarbon vapors are directed irom coil I03 while the cracking reaction is reactor A, they are supplied I00 through line I06 and valve I01.-'while'the is taking place in reactor B, the stream of heatedhydrocarbons from coil I03 is directed'thereto from line I05 through line I08 and valve I01.

Reactors A and B are of the improved form provided by the inventionwherein the catalyst mass in each reactor is divided into a plurality of relatively shallow beds through each of which a substantially equal portion or the stream of heated hydrocarbons supplied to the reactor is passed. Resulting conversion products from each 0! said relatively shallow beds are discharged from reactor A, while this reactor is employed for conducting the catalytic cracking reaction.

I08, valve I00 and line IIO to suitable separating and recovery equipment of any conventional form, which is not a novel part of the invention and is therefore not illustrated. while reactor B is employed for conducting the catalytic cracking reaction, the conversion products from each of the catalyst beds are disthis zone through line I08, valve IIO to the separating and recovery equipment.

During normal operation of the process, while catalytic cracking reactors reactivation of the catalyst is taking place in the other. To accomplish this, a. stream or relatively inert gas, such as nitrogen, combustion' gases substantially devoid of free oxygen, or the like, are directed from any suitable source through line III and valve this line with regulated amounts of oxygen or air supplied through line I I3 and valve Ill. The commingled gases from line I II are directed to heating 'coil IIS disposed in heater wherein oxygen conversion upon contact therewith in the reactor wherein reactivation is taking place. containing gases are directed from heater =II5 through line Iii and, while reactivation of the catalyst is taking place in reactor A, they are directed from line IIO through line I I1, valve II! and line I00 into this zone. While reactivation of the catalyst is taking place inreactor B, the heated oxygen-containing gases from line I I8 are supplied thereto through line III', valve IIO' andline Il0'.-

The oxygen-containing reactivating gases pass in the same manner as the heated hydrocarbon vapors, separate portions of through the separate relatively shallo beds of catalytic material in the reactors and burning therefrom the deposited heavy carbonaceous material. The resulting spent or partially spent reactivating gases and combustion products are discharged from re actor A, while reactivation is'taking place therein. through line, I00, line II! and valve I20 to line I2I. While reactivationis taking place in reactor 13, the spent or partial yspent ing gases and combustion products are directed substantially completely vathrough line I05 and,

taking place in; thereto from line is taking place in' one of the H2 and combine in The heated oxygenreactivattherefrom through line I08, line 9' and valve I20 to line I2I. The gases supplied to line I2I may be discharged from the system, preferably after heat is recovered therefrom for any de-' in which reactivation of the. catalyst is taking place. Such provisions are now common practice in the art and their illustration is not considered necessary.

When desired, instead of supplying air or oxygen to coil with the inert components of the reactivating gas stream, the air or oxygen may be added to the heated inert ingredients as they pass through line IIS bysupplying the same thereto through line 3' and valve III. This will help to avoidoxidation in the heating coil.

It will beunderstood, of course, that Fig. 4 is .only a diagrammatic illustration and that many modifications of the simple apparatus illustrated may be employed without departing from the scope of the invention. Heater I04, for example, is preferably one ofthe several well known conventional forms in which independent control of the temperature of the streams discharged from coils I03 and H5 is obtained or, when desired, separate heaters may be employed for heating the reactants and the reactivatlng gases. The invention also contemplates the use of more than two reactors, in which case two or more reactors may be connected for either parallel or series flow of the reactants and reactivating gases therethrough. Special stream diverting or switching valves which handle more than a single stream may also be employed within the scope of the invention to replace the switching valves here illustrated in a conventional manner. 7

The invention also definitely contemplates purging the reactor in which'catalytic cracking has been taking place of hydrocarbon vapors and gases prior to each reactivatlng period and purging the reactor in which reactivation has been purge the reactor of air and heat it to the desired temperature. Following such preconditioning of reactor A, the hot inert gases are diverted to reactor 13 to likewise precondition the same while the heated hydrocarbons from coil I03 are supplied to reactor A and the first cracking step of the operation is conducted in the latter. Following -the first cracking step in reactor A and preconditioning of reactor 13, the heated hydrocarbons are supplied to reactor B wherein the cracking; reaction is continued and the heated inert gases are supplied to reactor A for a sumcient length of time to substantially purge this reactor of hydrocarbon vapors and gases, than air is admitted to the stream of inert gases and reactivation of the catalyst in reactor A is accomplished while the cracking reaction continues in reactor B. Shortly before the cracking step in reactor B is completed, the supply of oxygen to the system is discontinued to purge reactor A of oxygen-containing gases and then the stream of heated hydrocarbons is diverted'to this reactor while the stream of hot inert gases is diverted to reactor B to purge it of hydrocarbon vapors and gases, oxygen is then again admitted to the sys-" tem to reactivate the catalyst in reactor B and from this point on the reactors are periodically alternated with purging in each reactor preceding each cracking step and each reactivatlng step therein.

As an example of one specific operation of the process provided by the invention, as applied to the catalytic cracking of hydrocarbon oil, the charging stock is a Mid-Continent parafilnic distillate of approximately 29 A. P. I. gravity having an initial boiling point of approximately 330 taking place of oxygen-containing gases prior to each cracking period. This is accomplished by discontinuing the supply of oxygen to the system for a short period immediately preceding and immediately following each alternation of the reactors to allow the relatively inert gases to sweep the hydrocarbon vapors and gases from the reactor in which reactivation is about to be initiated and to sweep the oxygen-containing gases from the reactor in which cracking is about to be initiated.

When starting the operation, the reactors are preferably preheated and otherwise preconditioned by circulating hot relatively inert gases from coil H5 therethrough. For example, if reactor A is to be first used for conducting the catalytic cracking operation, inert gases supplied to coil H5 through line Ill and valve H2, and heated therein to a temperature somewhat above that at which it is desired to conduct the cracking reaction, are supplied through line IIS, line "1,

valve H8 and line I06 to reactor A and therefrom through line I08, line 9 and valve I20 to line IZI for a sufficient length of time to substantially F. One volume of charging stock is combined with approximately 4.5 volumes of primary reflux condensate from the fractlonator of the system. This primary reflux condensate has an initial boiling point of about 490 F.- and a 50% boiling point of approximately 640 F. The mixture is substantially vaporized and heated prior to its introduction into the reactor, to which it is supplied at a temperature of about 935 F. The

average temperature in the reactor is approximately 912 F. and the combined feed (charging oil and primary reflux condensate) is supplied to the reactor at the rate of approximately 4 cubic feet per hour per cubic foot of space occupied by the catalyst. A superatmospheric pressure of approximately 30 pounds per square inch is employed at the inlet of the reactor and the outlet pressure is approximately 28 pounds per square inch, superatmospheric.

During reactivation, combustion gases containing approximately 2.5% by volume of oxygen are supplied to the reactor at a temperature of approximately 1000 F. and a superatmospheric pressure of approximately '75 pounds per square inch. The average of the peak temperatures encountered during the reactivatlng steps is approximately 1295 F. and the pressure at the outlet of the reactor during reactivation is approximately pounds per square inch.

In an operation such as above described there may be obtained per barrel of charging oil em-.

ployed, approximately 64.5% of 400 F. end-point gasoline, after stabilization of the latter to a Reid vapor pressure of approximately 9 pounds per square inch. The octane number of this product.

boiling point of approximately 615 F. may be produced. The residual liquid product of the process may amount to approximately 3.5% by volume of the charging stock and have a gravity of approximately 17 A. P. I. and a Saybolt Universal viscosity of approximately'75 seconds at 122 F. The gaseous products of the process (exclusive of combustion gases and air) may contain approximately 22% of hydrogen and 11% of readily polymerizable oleflns which will yield an additional 5 to 6%, based on the charging oil, of good antiknock polymer gasoline by catalytic polymerization.

I claim as my invention:

1. A process which comprises introducing a stream 01 reactants to one end of a vertically elongated reactor containing spaced superimposed beds or contact the reactor from said end to the thereof in a generally vertical direction, dividing the reactants, within and along the inner periphery of the reactor into a plurality of separate streams of substantially equal volume, passing each of said separate streams through one of said beds from a point adjacent the inner periphery of the reactor to a point adjacent thevertical axis or the reactor and effecting reaction of the reactant streams during such passage throughthe more than material to flow through opposite end' contact material.

actor, and removing beds of contact material, removing each of the separate streams from contact with said material after it has passed through only one of said beds and comming ling the individual streams oi'Jreaction products along the vertical axis of the rethe reaction products as a single composite stream from the opposite end of the reactor. 1

2. The process as defined in claim 1 further characterized in that said reactants comprise hydrocarbons which are subjected to conversion in said beds of contact material.

3. The process as defined in claim 1 further characterized in that said reactants comprise vapors of a hydrocarbon oil and said contact material comprises a cracking catalyst, the vapors being cracked during passage through the beds of 4. The process as defined in claim 1 further characterized in that the contact material comprises a carbonized hydrocarbonconversion catalyst and the reactants being an oxygen-containing gas whose oxygen content is reacted with the carbonaceous matter on the catalyst during passage of the gas through said beds, whereby to regenerate the catalyst.

PERCY MATHER. 

